How to Control Material Loss Rate When Cooperating with UHPC Manufacturers? Full-Process Refined Management and Cost Reduction Strategies

In UHPC facade projects, the material loss rate is a key variable affecting overall cost. As the Qinglong Group, with 28 years of deep expertise in the UHPC field, we draw on refined management practices from large-scale projects such as the Wuhan Han Show Theatre and the Hainan International Convention and Exhibition Center, and believe that keeping the loss rate of UHPC across the entire process from production to installation within 3%-5% is a hallmark of high-quality cooperation. Controlling loss is not the responsibility of a single stage; rather, it must be achieved through a systematic “five-in-one” strategy of “design optimization, lean production, transport protection, precise installation, and surplus material management,” which requires close coordination among the owner, the designer, and the UHPC manufacturer (such as Qinglong Group).

The design phase is the source of loss control. Using BIM technology for integrated design and virtual pre-assembly, and optimizing facade panel dimensions so they match the modulus of standard UHPC slabs (commonly 3m×1.5m), can greatly reduce cutting allowances. At the same time, nodes such as window openings and reveal lines should be rationally designed to avoid a large number of non-standard shaped components. Qinglong Group's technical team often gets involved in the early stage of a project, using parametric design tools to raise material utilization to over 95%, reducing waste at its source.

Refined management of production and construction is key. In the factory, CNC nesting layout and intelligent cutting (such as waterjet cutting) are adopted to plan optimal cutting paths and keep offcuts to a minimum. During production, the mix ratio and process are strictly controlled to keep the rejection rate (due to issues such as air bubbles and color variation) below 0.5%. In transportation, custom steel frames and vacuum suction cups are used for fixing, together with flexible cushioning materials, keeping the transport breakage rate within 0.2%. On the installation site, 3D laser scanning for setting out and adjustable high-precision connection systems are employed to reduce on-site cutting and component scrapping caused by installation errors. Qinglong Group prepares a dedicated “Material Management Manual” for each project, specifying loss control targets and responsible persons for each stage.

Closed-loop management of surplus materials and waste is equally important. Large offcuts generated at the factory can be processed into small decorative components or repair materials; powdery waste generated on site is collected centrally, part of which can be used as subgrade fill. Through scientific whole-process control, UHPC projects can fully achieve the green construction goals of low loss and high efficiency. Partnering with a manufacturer with a mature management system such as Qinglong Group is the primary prerequisite for controlling loss and safeguarding project economics.